Collapsible box

ABSTRACT

A packaging structure comprising a collapsible box is provided. The packaging structure is easily transformed from a unconstructed form to a usable box and provides improved storage and transportation efficiencies. In one embodiment, the packaging structure comprises a lid portion comprising a top panel and a plurality of lid side portions; and a container portion comprising: a front panel, a bottom panel and a back panel foldably connected in sequence; a left side panel foldably connected to a left edge of the bottom panel; a right side panel foldably connected to a right edge of the bottom panel; and a plurality of connectors foldably connected between each side panel and each of the front panel and back panel respectively, wherein the container portion may be folded into a compact position which may be inserted into the lid portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority benefits under 35 U.S.C. §120 to co-pending U.S. patent application Ser. No. 10/348,136 filed Jan. 21, 2003. This related patent application is herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to a packaging structure. More particularly, the present invention relates to a collapsible box.

2. Description of the Related Art

Cardboard boxes are commonly utilized as containers and are generally available in many sizes and shapes. Many cardboard boxes are fully constructed by box manufacturers and delivered to customers as non-foldable boxes in ready-to-use forms. However, there are several disadvantages of a non-foldable cardboard box because the three-dimensional structure requires a large amount of space for transportation and storage, resulting in various economic inefficiencies. At the same time, an empty cardboard box may be easily damaged during transportation from the box manufacturer to its customers.

Foldable cardboard boxes, especially when designed as flat sheets, improve the storage and transportation inefficiencies. However, foldable cardboard boxes generally require several steps of manually folding and tucking various parts of the cardboard box to construct the box for use. Additionally, an adhesive (e.g., glue and/or tape) may be required to hold the foldable box after being constructed. However, these manual steps of constructing a foldable box generally require tremendous time and labor costs. For example, additional time spent to make a box by a store clerk who is completing a purchasing transaction results in generally unacceptable delays and inefficiencies at the check-out register. Such delays and inefficiencies may be reduced if the foldable boxes are made ahead of time so that the boxes are ready for use. However, the storage space requirements of fully constructed boxes again may present problems.

Therefore, there remains a need for a packaging structure which is easily transformed from a unconstructed form to a usable box. There also remains a need for a packaging structure which provides improved storage and transportation efficiencies.

SUMMARY OF THE INVENTION

Embodiments of the invention generally provide packaging structures which are easily transformed from a unconstructed form to a usable box and provide improved storage and transportation efficiencies.

In one embodiment, the packaging structure comprises a plurality of main body panels foldably connected; a lift panel foldably connected to a first panel of the main body panels; and a connector foldably connected between the lift panel and a second panel of the main body panels, wherein the lift panel and the connector are movably disposed between a substantially flat position and a lifted position.

In another embodiment, a packaging system is provided. The packaging system comprises a main body comprising a front panel, a bottom panel, a back panel, and a top panel foldably connected; a left side panel foldably connected to a left edge of the bottom panel; a right side panel foldably connected to a right edge of the bottom panel; and one or more connectors foldably connected between each side panel and one or more of the front panel and back panel.

In yet another embodiment, the packaging structure comprises a main body comprising a front panel, a bottom panel, a back panel, and a top panel foldably connected in sequence; a left side panel foldably connected to a left edge of the bottom panel; a right side panel foldably connected to a right edge of the bottom panel; a plurality of connectors foldably connected between the left side panel and the front and back panels and between the right side panel and the front and back panels; wherein the side panels are selectively foldable between a flat position against the bottom panel and an upright position which concurrently lifts the front and back panels to upright positions.

In yet another embodiment, a packaging system comprising a lid portion and a container portion is provided. The lid portion comprises a top panel and a plurality of lid side portions. The container portion comprises: a front panel, a bottom panel and a back panel foldably connected in sequence; a left side panel foldably connected to a left edge of the bottom panel; a right side panel foldably connected to a right edge of the bottom panel; and a plurality of connectors foldably connected between each side panel and each of the front panel and back panel respectively, wherein the container portion may be folded into a compact position which may be inserted into the lid portion.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.

It is to be noted, however,, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 is a top view of a collapsible box in a flat position according to one embodiment of the invention.

FIG. 2 is a perspective view of a collapsible box with side panels in transition to an upright position according to one embodiment of the invention.

FIG. 3 is a perspective view of a collapsible box with side panels in an upright position according to one embodiment of the invention.

FIG. 4 is a top view of a collapsible box in transition to a compact position according to one embodiment of the invention.

FIG. 5 is a schematic diagram illustrating components for assembling a collapsible box according to one embodiment of the invention.

FIG. 6 is a perspective view of a collapsible box with side panels in transition to an upright position according to another embodiment of the invention.

FIG. 7 is a schematic diagram illustrating components for assembling a collapsible box according to another embodiment of the invention.

FIG. 8 is a perspective view of a collapsible box in a folded position according to another embodiment of the invention.

FIG. 9 is a perspective view of a collapsible box having a container portion disposed in a lid portion according to another embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Embodiments of the invention generally provide packaging structures which are easily transformed from a unconstructed form to a usable box and provide improved storage and transportation efficiencies.

FIG. 1 is a top view of a collapsible box in a flat position according to one embodiment of the invention. The exemplar collapsible box described herein can be collapsed down to substantially flat layers of card board and may be further folded to improve efficiencies in storage and transportation of large quantities of the collapsible boxes. Although a rectangular collapsible box is illustrated, collapsible boxes having other shapes are also contemplated. Generally, the collapsible box 100 comprises a top panel 110, a back panel 120, a bottom panel 130, a front panel 140, a left side panel 150 and a right side panel 160. As shown in FIG. 1, the top panel 110, the back panel 120, the bottom panel 130 and the front panel 140 are foldably connected in sequence. In an unconstructed form, the panels provide a substantially flat layout with the side panels 150 and 160 disposed as a top layer. The top panel 110, the back panel 120, the bottom panel 130 and the front panel 140 forms a bottom layer (or main body layer).

In one embodiment, each panel may comprise medium or heavy weight cardboard, and sheets of paper (relatively much lighter weight compared to the cardboard) may be glued to the panels, with small gaps between adjacent panels (e.g., 1/32 to ⅛ inch gaps for 1/16 inch thick panels), to provide the foldable connections between the panels. Alternatively, the panels may be taped together by strips of plastic or paper tapes to provide the foldable connections between the panels. In one embodiment, for a rectangular box as shown in FIG. 1, foldable connections 170 exist between a bottom edge of the front panel and a front edge of the bottom panel, between a bottom edge of the back panel and a back edge of the bottom panel, between a back edge of the top panel and a top edge of the back panel, and between a bottom edge of each of the left and right side panels and the left and right edges, respectively, of the bottom panel.

A plurality of connectors 180 are disposed to connect the side panels 150 and 160 to the front and back panels 140 and 120. The connectors 180 facilitate lifting of the front and back panels 140 and 120 toward an upright position when the side panels 150 and 160 are being lifted to an upright position. In one embodiment, each connector 180 comprises a first and a second triangular panels 182 and 184 which are foldably connected to form a substantially square-shaped panel with a diagonal foldable connection 186. The first triangular panel 182 is fixedly attached (e.g., glued) to the interior surface of the front panel (or back panel), and the second triangular panel 184 is foldably connected to a side edge 190 of a side panel. In another embodiment, each connector 180 comprises a triangular panel 184 having a first side foldably connected to a side edge 190 of a side panel and a hypotenuse edge foldably connected to an interior surface of the front panel 140 (or back panel 120).

The collapsible box may also include an enclosure flap 200 which is foldably attached to a front edge 112 of the top panel 110. A releasable fastener 210 may be attached to the enclosure flap 200 and the front panel 140 to facilitate closure of the collapsible box 100. In one embodiment, the releasable fastener 210 comprises a magnetic fastener set (e.g., a set of two magnets or a set of a magnet and a metal piece). Other releasable fasteners are contemplated for releasably holding the enclosure flap (or the top panel) against the front panel.

To change the collapsible box 100 from a flat layout to a three-dimensional box, a user may lift the side panels 150 and 160 to an upright position. FIG. 2 is a perspective view of a collapsible box 100 with side panels 150 and 160 in transition to an upright position according to one embodiment of the invention. As the side panels 150 and 160 are lifted, the front panel 140 and the back panel 120 are concurrently lifted because of the connectors 180 between the side panels 150 and 160 and the front and back panels 140 and 120.

FIG. 3 is a perspective view of a collapsible box 100 with side panels 150 and 160 in an upright position according to one embodiment of the invention. With the side panels 150 and 160 held in the upright position, the collapsible 100 box may be filled with one or more objects to be stored in the box. For example, the collapsible box may be utilized in a gift shop, and a store clerk may place one or more purchased gift items into the collapsible box. The collapsible box 100 may include a decorated exterior, and additional gift wrapping would not be necessary, saving time and money for both the merchant and the customer. The collapsible 100 box may also be decorated with a store's emblem, logo or a trademark.

In another embodiment, the collapsible box 100 may be folded from a flat layout to a compact position to further facilitate storage and transport of large quantities of collapsible boxes. FIG. 4 is a perspective view of a collapsible box 100 in transition from a flat layout to a compact position according to one embodiment of the invention. To facilitate folding of the collapsible box 100, the foldable connection 170B between the back panel and the bottom panel may be extended to provide a wider gap which accommodates for the combined thickness of the side panel (one of 150 and 160) and the connector 180. In the compact position, a plurality of collapsible boxes are easily stored and/or transported, increasing efficiencies in storage space requirements and transportation costs.

FIG. 5 is a schematic diagram illustrating components for assembling a collapsible box according to one embodiment of the invention. As described in one embodiment above, the panels and the connectors may be glued to one or more sheets. For clarity and illustrative purposes, the dimensions of the panels are not shown in scale. In one embodiment, the enclosure flap 200, the top panel 110, the back panel 120, the bottom panel 130 and the front panel 140 may be glued in sequence onto a first sheet 510. The panels (including the enclosure flap) may be spaced apart sufficiently to provide desired foldable connections between the panels. A second sheet 520 may be glued to the left side panel 150 and the associated connectors 180 (each connector 180 having first and second triangular panels 182 and 184). A third sheet 530 may be glued to the right side panel 160 and the associated connectors 180 (each connector 180 having first and second triangular panels 182 and 184). After the panels have been glued to the sheets, respective triangular panels 182 (and portions of respective sheet glued thereon) may be glued to the front panel and the back panel. Additional tape (not shown) may be utilized to join the edges between the side panels 150, 160, respectively, with the bottom panel 130. Each of the sheets 510, 520, 530 may include excess edge portions 512, 522, 532 that may be wrapped around the edges and glued to enhance the look of the edges and the overall attractiveness of the box. Furthermore, the sheets 510, 520, 530 may include logos and/or designs for particular occasions (e.g., holidays, birthdays, etc.) to further enhance the attractiveness of the box. It is contemplated that the sheets 510, 520 and 530 may comprise a single sheet or a plurality of sheets to achieve the desire attractiveness or finished look of the box.

Although the described embodiment illustrates a rectangular box, it is contemplated that boxes having other shapes may be constructed utilizing connectors adapted to lift one or more panels as a user lifts one or more other panels foldably connected to the connectors. Furthermore, the orientation of the collapsible box as described is illustrative of one embodiment of the invention, and various orientations of the collapsible box are contemplated to accommodate the intended usage of the box.

FIG. 6 is a perspective view of a collapsible box with side panels in transition to an upright position according to another embodiment of the invention. In the embodiment shown in FIG. 6, the collapsible box 600 generally comprises a lid portion 602 and a container portion 604. The container portion 604 of the collapsible box 600 described herein may be collapsed down to substantially flat layers of card board and may be further folded and stored within the lid portion 602 to improve efficiencies in storage and transportation of large quantities of the collapsible boxes. Although a rectangular collapsible box is illustrated, collapsible boxes having other shapes are also contemplated. In one embodiment, the lid portion 602 includes a top panel 610 and lid side portions 612. The container portion 604 includes a back panel 620, a bottom panel 630, a front panel 640, a left side panel 650 and a right side panel 660. It is understood that the directional or orientation terms utilized herein are for illustrative purposes and that embodiments having other orientations are contemplated. As shown in FIG. 6, the back panel 620, the bottom panel 630 and the front panel 640 are foldably connected in sequence. In one embodiment, for a rectangular box, foldable connections 670 (670A-D) exist between a bottom edge of the front panel and a front edge of the bottom panel, between a bottom edge of the back panel and a back edge of the bottom panel and between a bottom edge of each of the left and right side panels and the left and right edges, respectively, of the bottom panel. In a flat layout position, the panels provide a substantially flat layout with the side panels 650 and 660 disposed as a top layer while the back panel 620, the bottom panel 630 and the front panel 640 forms a bottom layer (or main body layer).

A plurality of connectors 680 are disposed to connect the side panels 650 and 660 to the front and back panels 640 and 620. The connectors 680 facilitate lifting of the front and back panels 640 and 620 toward an upright position when the side panels 650 and 660 are being lifted to an upright position. In one embodiment, each connector 680 comprises a first and a second polygonal panels 682 and 684 which are foldably connected with a foldable connection 686. The first polygonal panel 682 is fixedly attached (e.g., glued) to the interior surface of the front panel (or back panel), and the second polygonal panel 684 is foldably connected to a side edge 690 of a side panel.

In one embodiment, each panel may comprise medium or heavy weight cardboard, and sheets of paper (relatively much lighter weight compared to the cardboard) may be glued to the panels, with small gaps between adjacent panels (e.g., 1/32 to ¼ inch gaps for 1/16 inch thick panels), to provide the foldable connections between the panels. Alternatively, the panels may be taped together by strips of plastic or paper tapes to provide the foldable connections between the panels. FIG. 7 is a schematic diagram illustrating components for assembling a collapsible box 600 according to another embodiment of the invention. The panels (including the panels of the connector) may be fixedly attached (e.g., glued) to one or more sheets. For clarity and illustrative purposes, the dimensions of the panels are not shown in scale.

In one embodiment, the top panel 610 may be glued to a first sheet 710 which serves to cover an outer surface of the lid portion 602 and hold the lid side portions 612 in folded (e.g., orthogonal) positions against each other and the top panel 610. The first sheet 710 may include excess edge portions 712 that may be wrapped around the edges of the lid side portions 612 and may be glued to an inner surface of the assembled lid portion 602. A second sheet 720 may be utilized so that both outer and inner surfaces of the assembled lid portion 602 are covered. The second sheet 720 may be glued to an inner surface of the lid portion 602.

A third sheet 730 may be utilized to adhere the panels of the container portion 604. The panels (including the panels of the connector) may be spaced apart sufficiently for the sheet to provide desired foldable connections between the panels. For example, the side panels 650, 660 may be spaced apart from the bottom panel 630 so that the side panels 650, 660 may be folded flat against the bottom panel 630. As another example, more spacing may be needed between the front panel 640 and the bottom panel 630 and also between the back panel 620 and the bottom panel 630 so that these panels may be folded as a tri-fold, and the foldable connections 690 between the side panels 650, 660 and respective connectors 680 may also provide additional spacing required for a tri-fold folding position as described below. The third sheet 730 may include excess edge portions 732 which may be wrapped around the outer edges of the panels as laid out for assembly. Optionally, a fourth sheet (not shown) may be glued to the remaining exposed panel surfaces after the panels have been glued to the third sheet 730. The fourth sheet may serve to provide a decorated interior surface for the container portion 604. After the panels (including the panels of the connectors) have been glued to the sheets (e.g., 710, 720, 730), the side panels 650, 660 and the associated connectors may be folded, and the polygonal panel 682 may be glued against respective front panel 640 and back panel 620.

To construct the container portion 604 from a flat layout to a three-dimensional box, a user may lift the side panels 650 and 660 to an upright position. As the side panels 650 and 660 are lifted, the front panel 640 and the back panel 620 are concurrently lifted because of the connectors 680 between the side panels 650 and 660 and the front and back panels 640 and 620. The lid portion 602 may be placed over the opening of the container portion 604 and keep the container portion 604 from collapsing. Alternatively, to keep the container portion 604 in the constructed form (i.e., as a three-dimensional box), strips of double-sided tape 688 may be disposed between the polygonal panels 682 and 684. In one embodiment, the double-sided tape strips 688 may be adhered to one of each corresponding pair of polygonal panels 682 and 684 with peelable covers that may be peeled off to expose the tape strips when the box is ready to be used. Other tapes and fasteners are contemplated also.

FIG. 8 is a perspective view of a collapsible box in transition to a folded position according to another embodiment of the invention. To fold the container portion 604 into a tri-fold position, the container portion 604 may be collapsed into a flat layout position, and then the front panel 640 and the back panel 620 (in sequence depending on the lengths of respective foldable connections 670A and 670B) may be folded successively beneath the bottom panel 630. With the container portion 604 folded into a tri-fold position, the container portion 604 may be stored into the lid portion 602 in a compact position as shown in FIG. 9. In one embodiment, the height of the lid side portions 612 and the thickness of a container portion 604 in a tri-fold position may be substantially the same to provide efficiencies in costs of manufacturing, packaging, transportation, etc. In the compact position, a plurality of collapsible boxes are easily stored and/or transported, increasing efficiencies in storage space requirements and transportation costs.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. 

1. A packaging system, comprising: a lid portion comprising a top panel and a plurality of lid side portions; and a container portion comprising: a front panel, a bottom panel and a back panel foldably connected in sequence; a left side panel foldably connected to a left edge of the bottom panel; a right side panel foldably connected to a right edge of the bottom panel; and a plurality of connectors foldably connected between each side panel and each of the front panel and back panel respectively, wherein the container portion may be folded into a compact position which may be inserted into the lid portion.
 2. The packaging system of claim 1, further comprising: one or more sheets fixedly attached to the front panel, the bottom panel and the back panel in a spaced relationship to provide one or more foldable connections therebetween.
 3. The packaging system of claim 1, wherein each connector comprises a first polygonal panel having a first edge foldably connected to one of left and right side panels and a second edge foldably connected to one of front and back panels.
 4. The packaging system of claim 1, wherein each connector comprises a first polygonal panel foldably connected to a second polygonal panel, the first polygonal panel having a first edge foldably connected to one of left and right side panels and the second polygonal panel being fixedly attached to one of front and back panels.
 5. The packaging system of claim 1, wherein the container portion may be folded into a tri-fold position.
 6. The packaging system of claim 5, wherein the front panel and the back panel may be folded in sequence beneath the bottom panel. 